Barrier Coating Corrosion Control Methods and Systems for Interior Piping Systems

ABSTRACT

Methods and systems for providing cleaning and providing barrier coatings to interior wall surfaces of small diameter metal and composite piping systems in buildings. An entire piping system can be cleaned in one single pass by dry particulates forced by air throughout the building piping system by an external generator, and the entire piping system can be coated in one single pass by a machine connected exterior to the piping system. Small pipes can be protected by the effects of water corrosion, erosion and electrolysis, extending the life of piping systems such as copper, steel, lead, brass, cast iron piping and composite materials. Coatings can be applied to pipes having diameters of approximately ⅜″ up to approximately 6″ so that entire piping systems such as potable water lines, natural gas lines, HVAC piping systems, drain lines, and fire sprinkler systems in single-family homes to apartments to high-rise hotel/resort facilities and office towers, apartment and condominium buildings and schools, can be cleaned and coated to pipes within existing walls. The coating forms an approximately 4 mils or greater covering inside of pipes. Buildings can return to service within approximately 24 to approximately 96 hours.

This application is a Divisional application of U.S. patent applicationSer. No. 13/210,659 filed Aug. 16, 2011, which is a Divisionalapplication of U.S. patent application Ser. No. 12/947,012 filed Nov.16, 2010, now U.S. Pat. No. 8,354,140, which is a Divisional applicationof U.S. patent application Ser. No. 12/378,670 filed Feb. 18, 2009, nowU.S. Pat. No. 8,206,783, which is a Divisional application of U.S.patent application Ser. No. 11/246,825 filed Oct. 7, 2005, now U.S. Pat.No. 7,517,409, which is a Divisional application of U.S. patentapplication Ser. No. 10/649,288 filed Aug. 27, 2003, now U.S. Pat. No.7,160,574, which claims the benefit of priority to U.S. ProvisionalPatent Application 60/406,602 filed Aug. 28, 2002. The entire disclosureof each of the applications listed in this paragraph are incorporatedherein by specific reference thereto.

FIELD OF INVENTION

This invention relates to piping repair and restoration, and inparticular to methods, systems and apparatus for cleaning and providingbarrier protective coatings to the interior walls of small metal andplastic type pipes such as drain lines, hot water lines, cold waterlines, potable water lines, natural gas lines, HVAC piping systems,drain lines, and fire sprinkler system lines, and the like, that areused in multi-unit residential buildings, office buildings, commercialbuildings, and single family homes, and the like.

BACKGROUND AND PRIOR ART

Large piping systems such as those used in commercial buildings,apartment buildings, condominiums, as well as homes and the like thathave a broad base of users commonly develop problems with their pipessuch as their water and plumbing pipes, and the like. These problems caninclude leaks caused by pipe corrosion and erosion, as well as blockagefrom mineral deposits that develop over time where materials build updirectly inside the pipes. Presently when a failure in a piping systemoccurs the repair method may involve a number of applications. Thoserepair applications may involve a specific repair to the area of failuresuch as replacing that section of pipe or the use of a clamping deviseand a gasket. In some cases the complete piping system of the buildingmay need to be replaced.

In the case of pipes where the water flow has been impeded by rust buildup or by a deposit build up such as calcium and other minerals, variousmethods for the removal of the rust or other build up have been used.However the damage caused by the rust or from other deposits to the pipewall cannot be repaired unless the pipe is replaced.

Traditional techniques to correct for the corrosion, leakage andblockage problems have included replacing some or all of a building'spipes. In addition to the large expense for the cost of the new pipes,additional problems with replacing the pipes include the immense laborand construction costs that must be incurred for these projects.

Most piping systems are located behind finished walls or ceilings, underfloors, in concrete or underground. From a practical viewpoint simplygetting to the problem area of the pipe to make the repair can createthe largest problem. Getting to the pipe for making repairs can requiretearing up the building, cutting concrete and/or having to dig holesthrough floors, the foundation or the ground. These labor intensiverepair projects can include substantial demolition of a buildings wallsand floors to access the existing piping systems. For example, tearingout the interior walls to access the pipes is an expected result of thedemolition.

Once the walls and floors have been opened, then the old pipes areusually pulled out and thrown out as scrap, which is then followed byreplacement with new pipes. These prior techniques do little if nothingto reuse, refix, or recycle the old pipes.

In addition, there are usually substantial costs for removing the debrisand old pipes from the worksite. With these projects both the cost ofnew pipes and the additional labor to install these pipes are requiredexpenditures. Further, there are additional added costs for thematerials and labor to replumb these new pipes along with the necessarywall and floor repairs that must be made to clean up for the demolitioneffects. For example, getting at and fixing a pipe behind drywall is notcompleting the repair project. The drywall must also be repaired, andjust the drywall type repairs can be extremely costly. Additionalexpenses related to the repair or replacement of an existing pipingsystem will vary depending primarily on the location of the pipe, thebuilding finishes surrounding the pipe and the presence of hazardousmaterials such as asbestos encapsulating the pipe. Furthermore, theseprior known techniques for making piping repair take considerableamounts of time that can include many months or more to be completedwhich results in lost revenue from tenants and occupants of commercialtype buildings since tenants cannot use the buildings until theseprojects are completed.

Finally, the current pipe repair techniques are usually only temporary.Even after encountering the cost to repair the pipe, the cost andinconvenience of tearing up walls or grounds and if a revenue propertythe lost revenue associated with the repair or replacement, the new pipewill still be subject to the corrosive effects of fluids such as waterthat passes through the pipes.

Over the years many attempts have been proposed for cleaning water typepipes with chemical cleaning solutions. See for example, U.S. Pat. No.5,045,352 to Mueller; U.S. Pat. No. 5,800,629 to Ludwig et al.; U.S.Pat. No. 5,915,395 to Smith; and U.S. Pat. No. 6,345,632 to Ludwig etal. However, all of these systems require the use of chemical solutionssuch as liquid acids, chlorine, and the like, that must be run throughthe pipes as a prerequisite prior to any coating of the pipes. TheNational Sanitation Foundation (NSF) specifically does not allow the useof any chemical agent solutions for use with cleaning potable waterpiping systems. Thus, these systems cannot be legally used in the UnitedStates for cleaning out water piping systems.

Other systems have been proposed that use dry particulate materials as acleaning agent that is sprayed from mobile devices that travel throughor around the pipes. See U.S. Pat. No. 4,314,427 to Stolz; and U.S. Pat.No. 5,085,016 to Rose. However, these traveling devices require largediameter pipes to be operational and cannot be used inside of pipes thatare less than approximately 6 inches in diameter, and would not be ableto travel around narrow bends. Thus, these devices cannot be used insmall diameter pipes found in potable water piping systems that alsohave sharp and narrow bends.

The proposed systems and devices referenced above generally requiresectioning a small pipe length for cleaning and coating typeapplications, or limiting the application to generally straightelongated pipe lengths. For large building such as multistoryapplications, the time and cost to section off various piping sectionswould be cost prohibitive. None of the prior art is known to be able toservice an entire building's water type piping system at one time in onecomplete operation.

Thus, the need exists for solutions to the above problems with fixingexisting piping systems in buildings.

SUMMARY OF THE INVENTION

A primary objective of the invention is to provide methods, systems anddevices for repairing interior walls of pipes in buildings withouthaving to physically remove and replace the pipes.

A secondary objective of the invention is to provide methods, systemsand devices for repairing interior walls of pipes by initially cleaningthe interior walls of the pipes.

A third objective of the invention is to provide methods, systems anddevices for repairing interior walls of pipes by applying a corrosionprotection barrier coating to the interior walls of the pipes.

A fourth objective of the invention is to provide methods, systems anddevices for repairing interior walls of pipes in buildings in a costeffective and efficient manner.

A fifth objective of the invention is to provide methods, systems anddevices for repairing interior walls of pipes which is applicable tosmall diameter piping systems from approximately ⅜″ to approximately 6″in piping systems made of various materials such as galvanized steel,black steel, lead, brass, copper or other materials such as compositesincluding plastics, as an alternative to pipe replacement.

A sixth objective of the invention is to provide methods, systems anddevices for repairing interior walls of pipes which is applied to pipes,“in place” or insitu minimizing the need for opening up walls, ceilings,or grounds.

A seventh objective of the invention is to provide methods, systems anddevices for repairing interior walls of pipes which minimizes thedisturbance of asbestos lined piping or walls/ceilings that can alsocontain lead based paint or other harmful materials.

An eighth objective of the invention is to provide methods, systems anddevices for repairing interior walls of pipes where once the existingpiping system is restored with a durable epoxy barrier coating thecommon effects of corrosion from water passing through the pipes will bedelayed if not stopped entirely.

A ninth objective of the invention is to provide methods, systems anddevices for repairing interior walls of pipes to clean out blockagewhere once the existing piping system is restored, users will experiencean increase in the flow of water, which reduces the energy cost totransport the water. Additionally, the barrier epoxy coating beingapplied to the interior walls of the pipes can create enhanced hydrauliccapabilities again giving greater flow with reduced energy costs.

A tenth objective of the invention is to provide methods, systems anddevices for repairing interior walls of pipes where customers benefitfrom the savings in time associated with the restoration of an existingpiping system.

An eleventh objective of the invention is to provide methods, systemsand devices for repairing interior walls of pipes where customersbenefit from the economical savings associated with the restoration ofan existing piping system, since walls, ceilings floors, and/or groundsdo not always need to be broken and/or cut through.

A twelfth objective of the invention is to provide methods, systems anddevices for repairing interior walls of pipes where income producingproperties experience savings by remaining commercially usable, and anyoperational interference and interruption of income-producing activitiesis minimized.

A thirteenth objective of the invention is to provide methods, systemsand devices for repairing interior walls of pipes where health benefitshad previously accrued, as the water to metal contact will be stopped bya barrier coating thereby preventing the leaching of metallic andpotentially other harmful products from the pipe into the water supplysuch as but not limited to lead from solder joints and from lead pipes,and any excess leaching of copper, iron and lead.

A fourteenth objective of the invention is to provide methods, systemsand devices for repairing interior walls of pipes where the pipes arebeing restored in-place thus causing less demand for new metallic pipes,which is a non-renewable resource.

A fifteenth objective of the invention is to provide methods, systemsand devices for repairing interior walls of pipes using a less intrusivemethod of repair where there is less building waste and a reduced demandon expensive landfills.

A sixteenth objective of the invention is to provide methods, systemsand devices for repairing interior walls of pipes where the process usesspecially filtered air that reduces possible impurities from enteringthe piping system during the process.

A seventeenth objective of the invention is to provide methods, systemsand devices for repairing interior walls of pipes where the equipmentpackage is able to function safely, cleanly, and efficiently in highcustomer traffic areas.

An eighteenth objective of the invention is to provide methods, systemsand devices for repairing interior walls of pipes where the equipmentcomponents are mobile and maneuverable inside buildings and within theparameters typically found in single-family homes, multi unitresidential buildings and various commercial buildings.

A nineteenth objective of the invention is to provide methods, systemsand devices for repairing interior walls of pipes where the equipmentcomponents can operate quietly, within the strictest of noiserequirements such as approximately seventy four decibels and below whenmeasured at a distance of approximately several feet away.

A twentieth objective of the invention is to provide methods, systemsand devices for repairing interior walls of pipe where the barriercoating material for application in a variety of piping environments,and operating parameters such as but not limited to a wide temperaturerange, at a wide variety of airflows and air pressures, and the like.

A twenty first objective of the invention is to provide methods, systemsand devices for repairing interior walls of pipes where the barriercoating material and the process is functionally able to deliverturnaround of restored piping systems to service within approximatelytwenty four hours or less or no more than approximately ninety six hoursfor large projects.

A twenty second objective of the invention is to provide methods,systems and devices for repairing interior walls of pipes where thebarrier coating material is designed to operate safely under NSF(National Sanitation Foundation) Standard 61 criteria in domestic watersystems, with adhesion characteristics within piping systems in excessof approximately 400 PSI.

A twenty third objective of the invention is to provide methods, systemsand devices for repairing interior walls of pipes where the barriercoating material is designed as a long-term, long-lasting, durablesolution to pipe corrosion, pipe erosion, pinhole leak and related waterdamage to piping systems where the barrier coating extends the life ofthe existing piping system.

A twenty fourth objective of the invention is to provide methods,systems and devices for both cleaning and coating interiors of pipeshaving diameters of up to approximately 6 inches using dry particulates,such as sand and grit, prior to coating the interior pipe walls.

A twenty fifth objective of the invention is to provide methods, systemsand devices for both cleaning and coating interiors of pipes havingdiameters of up to approximately 6 inches in plural story buildings,without having to section off small sections of piping for cleaning andcoating applications.

A twenty sixth objective of the invention is to provide methods, systemsand devices for cleaning the interiors of an entire piping system in abuilding in a single pass run operation.

A twenty seventh objective of the invention is to provide methods,systems and devices for barrier coating the interiors of an entirepiping system in a building in a single pass run operation.

The novel method and system of pipe restoration prepares and protectssmall diameter piping systems such as those within the diameter range ofapproximately ⅜ of an inch to approximately six inches and can includestraight and bent sections of piping from the effects of watercorrosion, erosion and electrolysis, thus extending the life of smalldiameter piping systems. The barrier coating used as part of the novelprocess method and system, can be used in pipes servicing potable watersystems, meets the criteria established by the National SanitationFoundation (NSF) for products that come into contact with potable water.The epoxy material also meets the applicable physical criteriaestablished by the American Water Works Association as a barriercoating. Application within buildings ranges from single-family homes tosmaller walk-up style apartments to multi-floor concrete high-risehotel/resort facilities and office towers, as well as high-riseapartment and condominium buildings and schools. The novel methodprocess and system allows for barrier coating of potable water lines,natural gas lines, HVAC piping systems, hot water lines, cold waterlines, drain lines, and fire sprinkler systems.

The novel method of application of an epoxy barrier coating is appliedto pipes right within the walls eliminating the traditional destructivenature associated with a re-piping job. Typically 1 riser system orsection of pipe can be isolated at a time and the restoration of theriser system or section of pipe can be completed in less than one tofour days (depending upon the building size and type of application)with water restored within approximately 24 to approximately 96 hours.For hotel and motel operators that means not having to take rooms offline for extended periods of time. Too, for most applications, there areno walls to cut, no large piles of waste, no dust and virtually no lostroom revenue. Entire building piping systems can be cleaned within onerun through pass of using the invention. Likewise, an entire buildingpiping system can be coated within one single pass operation as well.

Once applied, the epoxy coating creates a barrier coating on theinterior of the pipe. The application process and the properties of theepoxy coating ensure the interior of the piping system is fully coated.Epoxy coatings are characterized by their durability, strength, adhesionand chemical resistance, making them an ideal product for theirapplication as a barrier coating on the inside of small diameter pipingsystems.

The novel barrier coating provides protection and extended life to anexisting piping system that has been affected by erosion corrosioncaused from internal burrs, improper soldering, excessive turns, andexcessive water velocity in the piping system, electrolysis and “wear”on the pipe walls created by suspended solids. The epoxy barrier coatingwill create an approximately 4 mil or greater covering to the inside ofthe piping system.

There are primarily 3 types of metallic piping systems that are commonlyused in the plumbing industry—copper, steel and cast iron. New steelpipes are treated with various forms of barrier coatings to prevent orslow the effects of corrosion. The most common barrier coating used onsteel pipe is the application of a zinc based barrier coat commonlycalled galvanizing. New copper pipe has no barrier coating protectionand for years was thought to be corrosion resistant offering a lifetimetrouble free use as a piping system.

Under certain circumstances that involved a combination of factors ofwhich the chemistry of water and installation practices a naturaloccurring barrier coating would form on the inside of copper pipes whichwould act as a barrier coating, protecting the copper piping systemagainst the effects of corrosion from the water.

In recent history, due to changes in the way drinking water is beingtreated and changes in installation practices, the natural occurringbarrier coating on the inside of copper pipe is not being formed or ifit was formed is now being washed away. In either case without anadequate natural occurring barrier coating, the copper pipe is exposedto the effects of corrosion/erosion, which can result in premature agingand failure of the piping system.

With galvanized pipe the zinc coating wears away leaving the pipeexposed to the effects of the corrosive activity of the water. Thisresults in the pipe rusting and eventually failing.

The invention can also be used with piping systems having plastic pipes,PVC pipes, composite material, and the like.

The novel method and system of corrosion control by the application ofan epoxy barrier coating to new or existing piping systems is apreventative corrosion control method that can be applied to existingpiping systems in-place.

The invention includes novel methods and equipment for providing barriercoating corrosion control for the interior walls of small diameterpiping systems. The novel process method and system of corrosion controlincludes at least three basic steps: Air Drying a piping system to beserviced; profiling the piping system using an abrasive cleaning agent;and applying the barrier coating to selected coating thickness layersinside the pipes. The novel invention can also include two additionalpreliminary steps of: diagnosing problems with the piping system to beserviced, and planning and setting up the barrier coating projectonsite. Finally, the novel invention can include a final end step ofevaluating the system after applying the barrier coating andre-assembling the piping system.

Further objects and advantages of this invention will be apparent fromthe following detailed description of the presently preferredembodiments which are illustrated schematically in the accompanyingdrawings.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows the general six steps that is an overview for applying thebarrier coating.

FIGS. 2A, 2B, 2C and 2D shows a detailed process flowchart using thesteps of FIG. 1 for providing the barrier coating.

FIG. 3 shows a side view of a multi-story story building using the novelbarrier coating corrosion control method and system of the invention.

FIG. 4 shows a side view of the novel exhaust air diffuser used in thebarrier coating control system in FIG. 3.

FIG. 5A shows a perspective view of the novel portable air distributionmanifold used in the barrier coating control system in FIG. 3.

FIG. 5B shows a side view of the novel Pressure Generator System(Sander) 500 used in the barrier coating control system of FIG. 3.

FIG. 5C is an enlarged view of the front control panel for use with thepressure generator system 500 of FIG. 5B.

FIG. 6A shows a side view of the novel Abrasive Reclaim Separator Module(Pre-Filter) used in the barrier coating control system of FIG. 3.

FIG. 6B shows an end view of the novel Abrasive Reclaim Separator Module(Pre-Filter) used in the barrier coating control system of FIG. 3.

FIG. 7A shows a side view of the novel Dust Collector System 700(Filter) used in the barrier coating control system of FIG. 3.

FIG. 7B shows an enlarged side cross-sectional view of the mountedCartridge Filters used in the Dust Collector System of FIG. 7A.

FIG. 8A shows a perspective view of the novel Portable Epoxy Meteringand Dispensing Unit 800 (Epoxy Mixer) used in the barrier coatingcontrol system of FIG. 3.

FIG. 8B shows another perspective view of the novel Portable EpoxyMetering and Dispensing Unit 800 (Epoxy Mixer) used in the barriercoating control system of FIG. 3.

FIG. 8C shows an enlarged view of the foot dispenser activator a part ofthe novel Portable Epoxy Metering and Dispensing Unit 800 (Epoxy Mixer)used in the barrier coating control system of FIG. 3.

FIG. 8D is an enlarged view of the mixing tubes and mixing head of FIG.8B

FIG. 9 shows a side view of the novel Main Air Header and Distributor200 (Header) used in the barrier coating control system of FIG. 3.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Before explaining the disclosed embodiments of the present invention indetail it is to be understood that the invention is not limited in itsapplication to the details of the particular arrangements shown sincethe invention is capable of other embodiments. Also, the terminologyused herein is for the purpose of description and not of limitation.

FIG. 1 shows the general six steps for a project overview for applyingthe barrier coating to an existing piping system, which include stepone, 10 program diagnosis, step two, 20 project planning, step three, 30drying piping system, step four 40, profiling the piping system, stepfive, 50 barrier coating interior walls of the pipes in the pipingsystem, and final step six 60 evaluation and return to operation of thepiping system.

Step One—Problem Diagnosis 10

For step one, 10, several steps can be done to diagnose the problem witha piping system in a building, and can include:

-   -   (a) Interview onsite engineering staff, property mangers, owners        or other property representatives as to the nature of the        current problem with the piping system.    -   (b) Evaluation of local and on-site water chemistry being used        in the piping system for hardness and aggressive qualities.    -   (c) Engineering evaluation, if necessary, to determine extent of        present damage to the wall thickness of the piping and overall        integrity of the piping system.    -   (d) Additional on-site testing of piping system, if necessary,        identifying leaks or the nature or extent of leaking.    -   (e) Corrosion control proposal development for client, including        options for pipe and fitting replacement where necessary.    -   After completion of step one, 10, the project planning and setup        step 20 can be started.

Step Two—Project Planning and Setup 20

For step two, 20, several steps can be followed for planning and setupfor restoring the integrity of the piping system in a building, and caninclude:

-   -   (a) Complete contract development with client, after the        diagnosis contract has started.    -   (b) Commence project planning with site analysis crew, project        management team, and on-site engineering/maintenance staff.    -   (c) Plan delivery of the equipment and supplies to the worksite.    -   (d) Complete equipment and supply delivery to worksite.    -   (e) Commence and complete mechanical isolation of the piping        system.    -   (f) Commence and complete set up of hosing and equipment.

Step Three—Air Drying—Step 1 Method of Corrosion Control 30

For step three, 30, the piping system to be prepared for the coating bydrying the existing pipes, and can include:

-   -   (a) Piping systems are mapped.    -   (b) Isolations of riser systems or pipe sections are prepared        and completed.    -   (c) The isolated piping system to receive the barrier coating is        adapted to be connected to the barrier coating equipment.    -   (d) The isolated riser system is drained of water.    -   (e) Using moisture and oil free, hot compressed air, a flushing        sequence is completed on the riser system to assure water is        removed.    -   (f) Riser system is then dried with heated, moisture and oil        free compressed air.    -   (g) Length of drying sequence is determined by pipe type,        diameter, length complexity, location and degree of corrosion        contained within the piping system, if any.    -   (h) Inspections are completed to assure a dry piping system        ready for the barrier coating.

Step Four—Piping System Profiling—Step 2 of Method of Corrosion Control40

For step four, 40, the piping system is to be profiled, and can include:

-   -   (a) Dried pipes can be profiled using an abrasive agent in        varying quantities and types. The abrasive medium can be        introduced into the piping system by the use of the moisture and        oil free heated compressed air using varying quantities of air        and varying air pressures. The amount of the abrading agent is        controlled by the use of a pressure generator.    -   (b) The abraded pipe, when viewed without magnification, must be        generally free of all visible oil, grease, dirt, mill scale, and        rust. Generally, evenly dispersed, very light shadows, streaks,        and discolorations caused by stains of mill scale, rust and old        coatings may remain on no more than approximately 33 percent of        the surface. Also, slight residues of rust and old coatings may        be left in the craters of pits if the original surface is        pitted.    -   (c) Pipe profiling is completed to ready the pipe for the        application of the barrier coating material.    -   (d) Visual inspections can be made at connection points and        other random access areas of the piping system to assure proper        cleaning and profiling standards are achieved.    -   (e) An air flushing sequence is completed to the riser system to        remove any residuals left in the piping system from the        profiling stage.

Step Five—Corrosion Control Epoxy Sealing and Protection of thePiping—Step 3 of the Method of Corrosion Control 50

For step five, 50, the piping system is to barrier coated and caninclude:

-   -   (a) Piping system can be heated with hot, pre-filtered, moisture        and oil free compressed air to an appropriate standard for an        epoxy coating application.    -   (b) Piping system can be checked for leaks.    -   (c) Corrosion control barrier coating material can be prepared        and metered to manufacturer's specifications using a        proportionator.    -   (d) Corrosion control barrier coating material can be injected        into the piping system using hot, pre-filtered, moisture and oil        free compressed air at temperatures, air volume and pressure        levels to distribute the epoxy barrier coating throughout the        pipe segment, in sufficient amounts to eliminate the water to        pipe contact in order to create an epoxy barrier coating on the        inside of the pipe.    -   (e) The epoxy barrier coating can be applied to achieve coating        of approximately 4 mils and greater.    -   (f) Once the epoxy barrier coating is injected warm,        pre-filtered, moisture and oil free compressed air can be        applied over the internal surface of the pipe to achieve the        initial set of the epoxy barrier coating.    -   (g) Confirm that all valves and pipe segments support        appropriate air flow indicating clear passage of the air through        the pipe i.e.: no areas of blockage. Allow the barrier coating        to cure to manufacturer's standards.

Step Six—System Evaluation and Re-Assembly 60

The final step six, 60 allows for restoring the piping system tooperation and can include:

-   -   (a) Remove all process application fittings.    -   (b) Examine pipe segments to assure appropriate coating        standards.    -   (c) Re-confirm that all valves and pipe segments support        appropriate air flow.    -   (d) Install original valves, fittings/fixtures, or any other        fittings/fixtures as specified by building owner representative.    -   (e) Reconnect water system, and water supply.    -   (f) Complete system checks, testing and evaluation of the        integrity of the piping system.    -   (g) Complete a water flush of system, according to        manufacturer's specifications.    -   (h) Evaluate water flow and quality.    -   (i) Document riser schedule, and complete pipe labeling.

FIGS. 2A, 2B, 2C and 2D show a detailed process flowchart using thesteps of FIG. 1 for providing the barrier coating. These flow chartfigures show a preferred method of applying a novel barrier coatingcorrosion control for the interior of small diameter piping systemsfollowing a specific breakdown of a preferred application of theinvention.

FIG. 3 shows a side view of a ten story building setup for using thenovel method and system of the invention. Components in FIG. 3 will nowbe identified as follows:

IDEN- TIFIER EQUIPMENT 100 395, 850, 1100, 1600 CFM CompressorsOutfitted with Aftercooler, Water separator, Fine Filter and Reheater200 Main Air Header and Distributor (Main Header) 300 Exhaust AirDiffuser (Muffler) 400 Portable Air Distribution Manifold (Floor Header)500 Pressure Generator System (Sander) 600 Reclaim Separator Module(Pre-Filter) 700 Dust Collector System (Filter) 800 Portable EpoxyMetering and Dispensing Unit (Epoxy Mixer) 900 Epoxy Barrier Coating

Referring to FIG. 3, components 100-800 can be located and used atdifferent locations in a ten story building. The invention allows for anentire building piping system to be cleaned in one single pass throughrun without having to dismantle either the entire or multiple sectionsof the piping system. The piping system can include pipes havingdiameters of approximately ⅜ of an inch up to approximately 6 inches indiameter with the piping including bends up to approximately ninetydegrees or more throughout the building. The invention allows for anentire building piping system to have the interior surfaces of the pipescoated in one single pass through run without having to dismantle eitherthe entire or multiple parts of the piping system. Each of thecomponents will now be defined.

100 Air Compressor

The air compressors 100 can provide filtered and heated compressed air.The filtered and heated compressed air employed in various quantities isused, to dry the interior of the piping system, as the propellant todrive the abrasive material used in cleaning of the piping system and isused as the propellant in the application of the epoxy barrier coatingand the drying of the epoxy barrier coating once it has been applied.The compressors 100 also provide compressed air used to propel ancillaryair driven equipment.

200 Main Air Header and Distributor

An off the shelf main header and distributor 200 shown in FIGS. 3 and 9can be one Manufactured By: Media Blast & Abrasives, Inc. 591 W. ApolloStreet Brea, Calif. 92821 The components of the main header anddistributor of FIG. 9 are labeled as follows.

Description of Main Header Equipment Describing Each Component:

-   -   12 & 14 Gauge Steel Construction    -   Approximate Dimensions: 28″ w×27″ l×53″ h    -   Ford Grabber Blue Powder-coating    -   Air Pressure Gauge 205    -   Regulator Adjustment 210    -   Air Pressure Regulator 215    -   Moisture Bleeder Valve 220    -   2 2″ NPT Inlet With Full Port Ball Valve 225    -   14—1″ Side-Mounted Ball Valves—Regulated Air 230    -   4—1″ Top Mounted Ball Valves—Unregulated Air 235    -   1—2″ Top Mounted full port Ball Valve—Unregulated Air 240    -   1—2″ Top Mounted Full Port Ball Valve—Regulated Air 245    -   1.9 Cubic Feet Pressure Pot 250    -   Insulated Cabinet 255    -   Two Inflatable Tires 260    -   Push/Pull Handles 265

Referring to FIGS. 3 and 9, the Main Header 200 provides safe airmanagement capability from the air compressor for both regulated andunregulated air distribution (or any combination thereof) to the variousother equipment components and to both the piping system risers andfixture outlets for a range of piping configurations from a singlefamily home to a multi-story building. The air enters through the 2″ NPTinlet, 225 to service the pressure vessel. The main header 200 canmanage air capacities ranging to approximately 1100 CFM andapproximately 125 psi.

There are many novel parts and benefits with the Main Header andDistributor 200. The distributor is portable and is easy to move andmaneuver in tight working environments. Regulator Adjustment 210 caneasily and quickly manage air capacities ranging to approximately 1600CFM and approximately 200 psi, and vary the operating airflows to eachof the other ancillary equipment associated with the invention. The AirPressure Regulator 210 and the Method of Distributing the air allowsboth regulated and unregulated air management from the same equipment ina user-friendly, functional manner. The approximately 1″ Valving 230,235, 245 allows accommodation for both approximately 1″ hosing and withadapters, and hose sizes of less than approximately 1″″ can be used tomeet a wide variety of air demand needs on a job site. The insulatedcabinet 255, surrounding air works dampens noise associated with themovement of the compressed air. The insulated cabinet 255, helps retainheat of the pre-dried and heated compressed air, the pre-dried andheated compressed air being an integral part of the invention. Theinsulated cabinet 255, helps reduce moisture in the pressure vessel andair supply passing through it. Finally, the valving of the pressurevessel allows for delivery (separate or simultaneous) of regulated airto the side mounted air outlet valves 230, the top mounted regulated airoutlet valves 245, as well as the top mounted unregulated air outletvalves 235 and 240.

FIG. 4 shows a side view of the novel exhaust air diffuser 300 used inthe barrier coating control system in FIG. 3.

300 Exhaust Air Diffuser (Muffler)

Referring to FIGS. 3 and 4, an exhaust air diffuser and muffler 300 thatcan be used with the invention can be one Manufactured By: Media Blast &Abrasives. Inc. 591 W. Apollo Street, Brea, Calif. 92821.

Description of Muffler 300 components:

-   -   12 & 14 Gauge Steel Construction    -   Approximate Dimensions: 34″ w×46″ l×76″ h    -   Ford Grabber Blue Powder-coating    -   Vented Access Panels on Both Sides of Unit 305    -   Vented End Panels 310    -   Dust Drawer with Removable Pan 315    -   Canvas Dust Bag Diffusers 320    -   2″ NPT Inlet 325    -   4″×8″ Expansion Chamber 330    -   Overhead Plenum 335    -   Two Swivel Casters 340    -   Two Locking Casters 350    -   Push/Pull Handles 360

Referring to FIGS. 3 and 4, the Air Diffuser/Muffler 300 allows thesafe, wholesale dumping of unregulated or regulated air from thecompressor off of the Main Header 200 through the approximately 2″ NPTinlet, into the expansion chamber and canvas dust bag diffusers for thepurpose of controlling the air temperature in the piping system duringthe drying phase, the pipe warming phase, the epoxy application phaseand the initial curing phase of the epoxy barrier coating material afterit is injected into the piping system. The Air diffuser 300 caneliminate the need to operate the air filter 600 during various stagesof the process, promoting energy efficiency as the filter 600 is an airassisted and electrically powered piece of invention.

There are many novel parts and benefits to the Exhaust air diffuser 300.The diffuser's portability allows for easy to move and maneuver in tightworking environments. Vented access panels 305 allow for safe and evendistribution of the air upon venting, prevents the build up ofbackpressure of the venting air and reduces the noise of the ventingair. A Dust Drawer with Removable Pan 315 allows for easy clean out ofthe expansion chamber. A Canvas Dust Bag Diffuser 320 assures quiet,customer friendly discharge of air. An approximately 2″ NPT Inlet 325allows full range of air diffusion from approximately 1″ toapproximately 2″ discharge hoses. A 4″×8″ Expansion Chamber 330 allowsfor rapid dispersing of the air upon entering the Air Diffuser 300. Theexpansion chamber 330 permits the compressed air that enters thediffuser 300 to expand allowing for a more efficient and safe passage toexit, which reduces the noise of the air upon departure and helps reducethe build up of backpressure of the exiting air from the piping system.The Air Diffuser 300 promotes the rapid unrestricted movement of thecompressed air in volumes greater than approximately 1100 CFM and canoperate with air pressures greater than approximately 120 PSI. When usedin conjunction with the heated, pre-filtered compressed air of thecompressor 100, the use of the Air Diffuser 300 creates a more efficientmovement of the heated air, which results in a cost savings by dryingthe pipes faster, drying the epoxy faster, which in turn saves manpower,fuel and reduces the operational time of the compressor 100.

FIG. 5A shows a preferred portable air distribution manifold 400 thatcan be used in the exemplary setup shown in FIG. 3

400 Portable Air Distribution Manifold

Referring to FIGS. 3 and 5A, an on off-the-shelf manifold 400 can be oneManufactured By: M & H Machinery 45790 Airport Road, Chilliwack, BC,Canada Description of Manifold 400 Components:

-   -   Main Air Cylinder 2½″×12″ Schedule 40 Steel Construction    -   Ford Grabber Blue Paint Finishes    -   4—1″ Welded Nipples Placed at a 45° Angle to the Base Cylinder;        Male Threaded 410    -   1″ NPT Female Threaded Portals at Each End of Cylinder 420    -   2 Metal Legs for Support and Elevation of Manifold 430    -   Pressure Rated Vessels to 125 PSI or Greater 440    -   Attached for Air Control, 1″ Full Port Ball Valves NPT; Female        Threaded 450    -   All Hose End Receptors are NPT 1″; Female Threaded 460

As part of the general air distribution system set up, the floormanifolds 400 can be pressure rated vessels designed to evenly andquietly distribute the compressed air to at least 5 other points ofconnection, typically being the connections to the piping system.Airflow from each connection at the manifold is controlled by the use ofindividual full port ball valves.

There are many novel parts and benefits to the Air Manifold 400. Theportability of manifold 400 allows for easy to move and maneuver intight working environments. The elevated legs 430 provide a stable basefor unit 400 as well as keep the hose end connections off the floor withsufficient clearance to permit the operator ease of access when havingto make the hose end connections. The threaded nipples 410 placed atapproximately 45° angle allow for a more efficient use of space and lessrestriction and constriction of the airline hoses they are attached to.Multiple manifolds 400 can be attached to accommodate more than 5outlets. The manifolds can be modular and can be used as 1 unit or canbe attached to other units and used as more than 1.

FIG. 5B shows a perspective view of the novel pressure generator sandersystem 500 used in the barrier coating control system in FIG. 3. FIG. 5Cshows the front control panel of the sander system.

500 Pressure Generator System-Sander

Referring to FIGS. 3, 5B and 5C, a pressure generator sander 500 thatcan be used with the invention can be one Manufactured By: Media Blast &Abrasives, Inc. 591 W. Apollo Street Brea, Calif. 92821.

Description of Sander 500 Components:

-   -   12 & 14 Gauge Steel Construction    -   Approximate Dimensions: 20″ w×24″ l×42″ h    -   Ford Grabber Blue Powder-coating    -   1—1″ NPT Inlets 505    -   1—1″ NPT Outlet 510    -   3—Air Breather Mufflers 515    -   Pop-up Valve gasket 520    -   Pop-up Valve 525    -   Hand Port Gasket 530    -   Pressure Pot with Hand Port and Hopper 535    -   Filler Lid with Latches 540    -   Mixing Valve 545    -   Remote Regulator 550    -   Process Valve 555    -   Toggle Switch 560    -   Air Pressure Gauge 565    -   Regulator Adjustment 570    -   Pulse Button 580    -   Wheel Assembly 585    -   2—Inflatable Tires 590

The pressure generating sander system 500 can provide easy loading andcontrolled dispensing of a wide variety of abrasive medium in amounts upto approximately 1.3 US gallons at a time. The pressure generator sandercan include operational controls that allow the operator to easilycontrol the amount of air pressure and control the quantity of theabrasive medium to be dispersed in a single or multiple application. Theabrasive medium can be controlled in quantity and type and is introducedinto a moving air steam that is connected to a pipe or piping systemsthat are to be sand blasted clean by the abrasive medium. The sand canbe introduced by the pressure generator sander system 500 by beingconnected to and be located outside of the piping system depicted inFIG. 3. The novel application of the sander system 500 allows forcleaning small pipes having diameters of approximately ⅜″ up toapproximately 6″.

Table 1 shows a list of preferred dry particulate materials with theirhardness ratings and grain shapes that can be used with the sandgenerator 500, and Table 2 shows a list of preferred dry particulateparticle sieve sizes that can be used with the invention.

TABLE 1 PARTICULATES Material Hardness Rating Grain Shape Diamond 10Cubical Aluminium Oxide 9 Cubical Silica 5 Rounded Garnet 5 RoundedWalnut shells 3 Cubical

TABLE 2 PARTICULATE SIZE SIEVE SIZE OPENING U.S. Mesh Inches MicronsMillimeters 4 .187 4760 4.76 8 .0937 2380 2.38 16 .0469 1190 1.19 25.0280 710 .71 45 .0138 350 .35

There are many novel parts and benefits to the use of the PressureGenerator Sander System 500. The portability allows for easy to move andmaneuver in tight working environments. The sander 500 is able to accepta wide variety of abrasive media in a wide variety of media size.Variable air pressure controls 570 in the sander 500 allows formanagement of air pressures up to approximately 125 PSI. A mixing Valve545 adjustment allows for setting, controlling and dispensing a widevariety of abrasive media in limited and controlled quantities, allowingthe operator precise control over the amount of abrasive medium that canbe introduced into the air stream in a single or multiple application.The filler lid 540, incorporated as part of the cabinet and the pressurepot allows the operator to load with ease, controlled amounts of theabrasive medium into the pressure pot 535. The pulse button 580 can beutilized to deliver a single sized quantity of the abrasive materialinto the air stream or can be operated to deliver a constant stream ofabrasive material in to the air stream. All operator controls and hoseconnections can be centralized for ease of operator use.

FIG. 6A shows a side view of the novel Abrasive Reclaim Separator Module(Pre-Filter) 600 used in the barrier coating control system of FIG. 3.FIG. 6B shows an end view of the novel Abrasive Reclaim Separator Module(Pre-Filter) 600 used in the barrier coating control system of FIG. 3.

600 Abrasive Reclaim Separator Module (Pre-Filter)

Referring to FIGS. 3, 6A and 6B, an off-the-shelf pre-filter that can beused with the invention can be one Manufactured By: Media Blast &Abrasives, Inc. 591 W. Apollo Street Brea, Calif. 92821

Description of Pre-Filter 600 Components:

-   -   12 & 14 Gauge Steel Construction    -   Approximate Dimensions: 23″ w×22″ l×36″ h    -   Ford Grabber Blue Powder-coating    -   Dust Drawer with Removable Pan 610    -   2—2″ NPT Inlets 620    -   Approximate Dimensions: 13¼″ w×13¼″ l×17″ h Cyclone        Chamber/Separator 630    -   8″ Air and Dust Outlet with Flexible Duct to Air Filter 640    -   Two Inflatable Tires 650    -   Push/Pull Handle 660

During the pipe profiling stage, the Pre-Filter 600 allows the filteringof air and debris from the piping system for more than two systems at atime through the 2—approximately 2″ NPT inlets 620. The cyclonechamber/separator 630 captures the abrasive material and large debrisfrom the piping system, the by products of the pipe profiling process.The fine dust particles and air escape through the approximately 8″ airand dust outlet 640 at the top of the machine and are carried to thedust collection equipment 700, which filters, from the exhausting air,fine particulates, that may not have been captured with the Pre-Filter600.

There are many novel parts and benefits to the Pre-Filter 600. Thepre-filter has portability and is easy to move and maneuver in tightworking environments. The Dust Drawer with Removable Pan 610 allows foreasy clean out of the abrasive media and debris from the pipe. TheCyclone Chamber/Separator 630 slows and traps the abrasive media anddebris from the piping system and air stream, and prevents excess debrisfrom entering into the filtration equipment. The 2—approximately 2″ NPTInlet 620 allows a full range of air filtration from two separate riseror piping systems. Use of the approximately 8″ or greater flex tube 640as an expansion chamber results in reducing the air pressure of the airas it leaves the pre-filter 600 and reduces the potential for backpressure of the air as it departs the pre-filter and enhances theoperational performance of the air filter. When used in conjunction withthe air filter 700, the Pre-filter 600 provides a novel way ofseparating large debris from entering the final stage of the filtrationprocess. By filtering out the large debris with the pre-filter 600 thispromotes a great efficiency of filtration of fine particles in the finalstages of filtration in the air filter 700. The approximately 8″ air anddust outlet 640 to the air filter 700 from the pre-filter 600 permitsthe compressed air to expand, slowing it in velocity before it entersthe air filter 700, which enhances the operation of the air filter 700.Process cost savings are gained by the use of the pre-filter 600 byreducing the impact of filtering out the large amounts of debris at thepre-filter stage prior to air entering the air filter 700. This providesfor greater operating efficiencies at the air filter 700 a reduction inenergy usage and longer life and use of the actual fine air filters 760used in the air filter 700.

700 Dust Collection Filter

Referring to FIGS. 3, 7A and 7B, an off-the-shelf example if a filter700 used with the invention can be one Manufactured By: Media Blast &Abrasives, Inc. 591 W. Apollo Street, Brea, Calif. 92821.

Description of Air Filter 700 Components:

-   -   12 & 14 Gauge Steel Construction    -   Approximate Dimensions: 24″ w×32″ l×65″ h    -   Ford Grabber Blue Powder-coating    -   Dust Drawer with Removable Pan and Tightening Knobs 705    -   1—¾ NPT Inlet 710    -   2.0 HP Baldor Motor, Volts 115/230 715    -   8″ Air and Dust Inlet with Flexible Duct to Pre-Filter 720    -   Ball Vibrator Muffler 725    -   2—Locking Wheels 730    -   2—Swivel and Locking Wheels 735    -   Pushbutton Switch 740    -   Mushroom Head Switch 745    -   Selector Switch 750    -   Tightening Knob 755    -   2—Corrugated Cartridge Filters, approximately 99.98% Efficient,        Collecting 0.5 Micron Particles (based on SAE-J726 test) 760    -   Cartridge Mounting Rods 765    -   Cartridge Mounting Plates 770    -   Filter Tightening Knobs 775    -   Filter Ball Tightening Knobs 780    -   Sliding Air Control Exit Vent 785

During the pipe profiling stage, the filter or dust collector 700 is thefinal stage of the air filtration process. The dust collector 700filters the passing air of fine dust and debris from the piping systemafter the contaminated air first passes through the pre-filter 600(abrasive reclaim separator module). During the epoxy coating dryingstage the filter 700 is used to draw air through the piping system,keeping a flow of air running over the epoxy and enhancing its dryingcharacteristics. The filter 700 creates a vacuum in the piping systemwhich is used as method of checking for airflow in the piping system,part of the ACE DuraFlo process. The dust collector 700 can be capableof filtering air in volumes up to approximately 1100 CFM.

There are many novel parts and benefits to the Air Filter 700. The airfilter has portability and is easy to move and maneuver in tight workingenvironments. The Dust Drawer with Removable Pan 705 allows for easyclean out of the abrasive media and debris from the filtration chamber.The 8″ flexible duct 640 (from FIG. 6A permits the compressed air toexpand and slow in velocity prior to entering the dust collector 700,enhancing efficiency. The sliding air control exit vent 785 permits useof a lower amperage motor on start up. The reduced electrical drawenables the dust collector 700 to be used on common household electricalcurrents while still being able to maintain its capacity to filter up toapproximately 1100 CFM of air. The air filter 700 keeps a flow of airrunning over the epoxy and enhancing its drying and curingcharacteristics. The dust collector 700 creates a vacuum in the pipingsystem, which is used as method of checking for airflow in the pipingsystem.

800 Portable Epoxy Metering and Dispensing Unit

Referring to FIGS. 3, 8A, 8B and 8C, a metering and dispensing unit 800used with the invention can be one Manufactured by: Lily Corporation,240 South Broadway, Aurora, Ill. 60505-4205.

Description of Metering and Dispensing Unit 800 Components:

-   -   Aluminum Frame And Cabinet Construction    -   Approximate Dimensions: 48″ L×48″ H×22″ W    -   Blue and Black Anodized Finishes    -   Electrical Powered Space Heating Element and Thermostat 805    -   Temperature Gauge 810    -   1—3 Gallon Stainless Steel Pressure Pot for Resin Part A 815    -   1—3 Gallon Stainless Steel Pressure Pot for Catalyst Part B 820    -   Pressure Valve For Each Tank 825    -   Side Door Access Panel 830    -   Parts and Tool Drawer 835    -   Aluminum Removable Cover To Access Pressure Pots 840    -   Adjustable Cycle or Shot Counter 845    -   4 Wheels—Swivel and Locking 850    -   Coalescing Air Filter 855    -   Air Pressure Regulator and Gauge 860    -   Foot Dispenser Activator 865    -   Abort Switch 870    -   On/Off Control Switch 875    -   Compressed Air Driven Epoxy Meter and Pump Adjustable for        Dispensing Up To 14.76 Oz of Mixed Epoxy Per Single Application.        Multiple Applications Can Dispense Up To 75 Gallons of Epoxy Per        Hour. 880    -   Threaded Epoxy Mixing Head To Accommodate Disposable Epoxy        Mixing Tubes 887 and mixing head 885.    -   Push/Pull Handle 890    -   Epoxy Carrying Tube Hanger 895

The Portable Epoxy Metering and Dispensing Unit 800 can store up toapproximately 3 US gallons of each of A and B component of the two mixcomponent epoxy, and can dispense single shots up to approximately 14.76oz, in capacities up to approximately 75 US gallons per hour.

The unit 800 can be very mobile and can be used both indoors andoutdoors, and it can operate using a 15 Amp 110 AC electrical servicei.e.: regular household current and approximately 9 cubic feet (CFM) at90 to 130 pounds per square inch. The unit 800 requires only a singleoperator.

The epoxy used with the unit 800 can be heated using this unit to itsrecommended temperature for application. The epoxy can be metered tocontrol the amount of epoxy being dispensed.

There are many novel parts and benefits to the Epoxy Metering andDispensing Unit 800, which include portability and is easy to move andmaneuver in tight working environments. The heated and insulted cabinet,all epoxy transit hoses, valves and pumps can be heated within thecabinet. The Top filling pressurized tanks 815 and 820 offers ease andaccess for refilling. Epoxy can be metered and dispensed accurately insingle shot or multiple shots having the dispensing capacity up toapproximately 14.76 ounces of material per shot, up to approximately 75gallons per hour. The position of mixing head 885, permits a singleoperator to fill the portable epoxy carrying tubes 887 in a single fastapplication. The drip tray permits any epoxy overspill at the time offilling to be contained in the drip tray, containing the spill andreducing cleanup. The epoxy carrying tube hanger 895 allows the operatorto fill and temporarily store filled epoxy tubes, ready for easydistribution. The pump 880 and heater 805 combination allows for theepoxy to metered “on ratio” under a variety of conditions such aschanges in the viscosity of the epoxy components which can differ due totemperature changes which effect the flow rates of the epoxy which candiffer giving the operator an additional control on placement of theepoxy by changing temperature and flow rates. Unit 800 overall providesgreater operator control of the characteristics of the epoxy in theprocess.

900 Epoxy Barrier Coating

Referring to FIGS. 3 and 8A, 8B and 8C, a preferred epoxy barriercoating that can be used with the invention can be one Manufactured by:CJH, Inc. 2211 Navy Drive, Stockton, Calif. 95206. The barrier coatingproduct used in this process can be a 2-part thermo set resin with abase resin and a base-curing agent.

The preferred thermo set resin is mixed as a two-part epoxy that is usedin the invention. When mixed and applied, it forms a durable barriercoating on pipe interior surfaces and other substrates. The barriercoating provides a barrier coating that protects those coated surfacesfrom the effects caused by the corrosive activities associated with thechemistry of water and other reactive materials on the metal and othersubstrates.

The epoxy barrier coating can be applied to create a protective barriercoating to pipes ranging in size approximately ⅜″ to approximately 6″and greater. The barrier coating can be applied around bendsintersections, elbows, t's, to pipes having different diameters and makeup. The barrier coating can be applied to pipes in any position e.g.:vertical or horizontal, and can be applied as a protective coating tometal pipes used in fire sprinkler systems and natural gas systems. Upto approximately 4 mils thick coating layers can be formed on theinterior walls of the pipes. The barrier coating protects the existinginterior walls and can also stop leaks in existing pipes which havesmall openings and cracks, and the like, of up to approximately ⅜^(th)″in diameters in size.

Although the process of application described in this invention includesapplication of thermo set resins other types of thermo set resins can beused.

For example, other thermo set resins can be applied in the process, andcan vary depending upon viscosity, conditions for application includingtemperature, diameter of pipe, length of pipe, type of material pipecomprised of, application conditions, potable and non potable watercarrying pipes, and based on other conditions and parameters of thepiping system being cleaned and coated by the invention.

Other thermo set type resins that can be used include but are notlimited to and can be one of many that can be obtained by numeroussuppliers such as but not including: Dow Chemical, Huntsmans AdvancesMaterial, formerly Ciba Giegy and Resolution Polymers, formerly ShellChemical.

Although the novel invention can be applied to all types of metal pipessuch as but not limited to copper pipes, steel pipes, galvanized pipes,and cast iron pipes, the invention can be applied to pipes made of othermaterials such as but not limited to plastics, PVC (polyvinyl chloride),composite materials, polybutidylene, and the like. Additionally, smallcracks and holes in plastic type and metal pipes can also be fixed inplace by the barrier coating.

Although the preferred applications for the invention are described withbuilding piping systems, the invention can have other applications suchas but not limited to include piping systems for swimming pools,underground pipes, in-slab piping systems, piping under driveways,various liquid transmission lines, tubes contained in heating andcooling units, tubing in radiators, radiant in floor heaters, chillersand heat exchange units, and the like.

While the invention has been described, disclosed, illustrated and shownin various terms of certain embodiments or modifications which it haspresumed in practice, the scope of the invention is not intended to be,nor should it be deemed to be, limited thereby and such othermodifications or embodiments as may be suggested by the teachings hereinare particularly reserved especially as they fall within the breadth andscope of the claims here appended.

We claim:
 1. A method of applying a barrier leak sealing coating tointeriors of pipes, comprising the steps of: injecting compressed airwith abrasive agents into an end of a pipe section of a metal pipingsystem, and collecting the air and agent at another end of the pipesection; cleaning and profiling interior surfaces of the pipe sectionwith the injected abrasive particles; injecting an epoxy leak barriercoating over the cleaned and profiled interior surfaces of the pipesection with the compressed air to form one barrier coating layer; andrestoring the pipe section to service within approximately 96 hours. 2.The method of claim 1, wherein the step of injecting the epoxy leakbarrier coating is one epoxy application phase
 3. The method of claim 1,wherein the one barrier coating layer is approximately 4 mils thick orgreater.
 4. The method of claim 1, further comprising the step of:applying warm filtered air over the interior surfaces of the pipe toachieve an initial set of the epoxy barrier coating.
 5. The method ofclaim 4, wherein step of applying the compressed air to achieve theinitial set is completed in a an initial curing phase.
 6. The method ofclaim 1, wherein the step of injecting the compressed air includes thestep of generating compressed air up to 1600 CFM and 200 psi.
 7. Themethod of claim 6, further comprising the step of: generating a vacuumat the collecting another end of the piping section.
 8. The method ofclaim 7, wherein the step of generating the vacuum includes the step ofgenerating the vacuum up to 1100 CFM and 125 psi.
 9. The method of claim1, wherein the cleaning and profiling step includes the step of:profiling the interior walls of the piping section wherein shadows,streaks and discolorations caused by stains of mill scale, rust and oldcoatings remain on no more than 33 percent of the surface.
 10. Themethod of claim 1, wherein the cleaning and profiling step includes thestep of: profiling the interior walls of the piping section whereinresidues of rust and old coatings remain left in craters of pits on theinterior surfaces.
 11. The method of claim 1, wherein the coatedinterior piping section includes adhesion qualities in excess ofapproximately 400 psi.
 12. The method of claim 1, wherein the coatedinterior piping section includes adhesion qualities of greater thanapproximately 2500 psi.
 13. The method of claim 1, wherein the metalbuilding pipes include copper pipes.
 14. The method of claim 1, whereinthe metal building pipes include pipes selected from at least one oflead pipes and iron pipes and galvanized pipes.
 15. A method of applyinga barrier leak sealing coating to interiors of pipes, comprising thesteps of: injecting compressed air with abrasive agents into a metalpipe section; cleaning and profiling interior surfaces of the pipesection with the injected abrasive particles; applying a barrier leaksealing coating in one epoxy application coating phase. to the interiorsurfaces of the pipe section with the compressed air.
 16. The method ofclaim 15, wherein the applying step includes the step of: forming onecoating layer with the barrier leak sealing coating.
 17. The method ofclaim 15, wherein the cleaning and profiling step includes the step of:profiling the interior walls of the piping section wherein shadows,streaks and discolorations caused by stains of mill scale, rust and oldcoatings remain on no more than 33 percent of the surface.
 18. Themethod of claim 15, wherein the cleaning and profiling step includes thestep of: profiling the interior walls of the piping section whereinresidues of rust and old coatings remain left in craters of pits on theinterior surfaces.
 19. The method of claim 15, wherein the coatedinterior piping section includes adhesion qualities in excess ofapproximately 400 psi.
 20. The method of claim 15, wherein the coatedinterior piping section includes adhesion qualities of greater thanapproximately 2500 psi.